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- Supplementary Service Manual
Suzuki SV650 Supplementary Service Manual
Summary of SV650
Page 1
Sv650/s/a/sa use this manual with: sv650 service manual (99500-36123-01e) 9 9 5 0 1 - 3 6 1 4 0 - 0 1 e.
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Sv650k7/sk7/ak7/sak7 (’07-model) 1 contents sv650k7/sk7/ak7/sak7 (’07-model) © copyright suzuki motor corporation 2006 this manual describes service data, service specifications, servicing procedures abs and ser- vicing procedures which differ from those of the sv650k6/sv650sk6 (’06-model). Note: • ...
Page 3
2 sv650k7/sk7/ak7/sak7 (’07-model) sv650k7/sk7/ak7/sak7 (’07-model) contents tp sensor adjustment .................................................................. 61 throttle valve synchronization ............................................ 62 isc valve ..............................................
Page 4: Country And Area Codes
Sv650k7/sk7/ak7/sak7 (’07-model) 3 country and area codes the following codes stand for the applicable country(-ies) and area(-s). Model code country or area effective frame no. Sv650 e-02 e-03 e-19 e-24 e-28 e-33 u.K. U.S.A. (except for california) e.U. Australia canada california (u.S.A.) js1by111...
Page 5: Manual
4 sv650k7/sk7/ak7/sak7 (’07-model) abbreviations used in this manual a abdc : after bottom dead center abs : anti-lock brake system ac : alternating current acl : air cleaner, air cleaner box api : american petroleum institute atdc : after top dead center a/f : air fuel mixture b bbdc : before botto...
Page 6
Sv650k7/sk7/ak7/sak7 (’07-model) 5 n nox : nitrogen oxides o ohc : over head camshaft ops : oil pressure switch p pair : pulsed secondary air injection pcv : positive crankcase ventilation (crankcase breather) r rh : right hand rom : read only memory s sae : society of automotive engineers sds : suz...
Page 7: Sae-to-Former Suzuki Term
6 sv650k7/sk7/ak7/sak7 (’07-model) sae-to-former suzuki term this table lists sae (society of automotive engineers) j1930 terms and abbreviations which may be used in this manual in compliance with sae recommendations, as well as their former suzuki names. Sae term former suzuki term full term abbre...
Page 8
Sv650k7/sk7/ak7/sak7 (’07-model) 7 sae term former suzuki term full term abbreviation i idle speed control isc –––– idle speed control valve –––– isc valve ignition control ic electronic spark advance (esa) ignition control module icm –––– intake air temperature iat intake air temperature (iat), air...
Page 9
8 sv650k7/sk7/ak7/sak7 (’07-model) specifications (sv650k7/sv650sk7) dimensions and dry mass overall length....................................................... 2 080 mm (81.9 in) ........................ Sv650 2 085 mm (82.1 in) ........................ Sv650s overall width .........................
Page 10
Sv650k7/sk7/ak7/sak7 (’07-model) 9 chassis front suspension................................................. Telescopic, coil spring, oil damped rear suspension ................................................. Link type, coil spring, oil damped front fork stroke .......................................
Page 11
10 sv650k7/sk7/ak7/sak7 (’07-model) specifications (sv650ak7/sv650sak7) dimensions and dry mass overall length..................................................... ** 2 120 mm (83.5 in) ........................ Sv650a ** 2 120 mm (83.5 in) ........................ Sv650sa overall width ................
Page 12
Sv650k7/sk7/ak7/sak7 (’07-model) 11 chassis front suspension................................................. Telescopic, coil spring, oil damped rear suspension ................................................. Link type, coil spring, oil damped front fork stroke ......................................
Page 13
12 sv650k7/sk7/ak7/sak7 (’07-model) periodic maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for...
Page 14: Maintenance And Tune-Up
Sv650k7/sk7/ak7/sak7 (’07-model) 13 maintenance and tune-up procedures this section describes the servicing procedures for each peri- odic maintenance item which differ from those of the sv650/sk6 (’06-model). For details other than the following items, refer to the sv650/s service manual. Spark plu...
Page 15
14 sv650k7/sk7/ak7/sak7 (’07-model) • remove the spark plugs with the special tool. " 09930-10121: spark plug socket wrench set no.2 (rear) spark plug removal • lift and support the fuel tank with its prop stay. ( #sv650/sk3 5-6) • remove the spark plug caps. • remove the spark plugs with the specia...
Page 16
Sv650k7/sk7/ak7/sak7 (’07-model) 15 spark plug gap • measure the plug gap with a thickness gauge. If out of specifi- cation, adjust it to the following gap. $ spark plug gap a standard: 0.7 – 0.8 mm (0.028 – 0.031 in) " 09900-20803: thickness gauge electrodes condition • check to see the worn or bur...
Page 17
16 sv650k7/sk7/ak7/sak7 (’07-model) engine components inspection and servicing for details other than the following, refer to the sv650/s service manual. Piston and piston ring $ piston ring groove width standard (1st) : 0.83 – 0.85 mm (0.0327 – 0.0335 in) 1 1.30 – 1.32 mm (0.0512 – 0.0520 in) 2 (2n...
Page 18
Sv650k7/sk7/ak7/sak7 (’07-model) 17 thermostat $ thermostat valve opening temperature standard: approx. 76.5 °c (170 °f) $ thermostat valve lift a standard: 8.0 mm and over at 90 °c (0.31 in and over at 194 °f) sa mp le.
Page 19: Fi System Diagnosis
18 sv650k7/sk7/ak7/sak7 (’07-model) fi system diagnosis fi system wiring diagram cr ankshaft position sensor (ckps) speedometer fuel pump rela y side-stand rela y star ter rela y star ter s w itch gear position s w itch n 6 5 4 3 2 1 throttle position sensor (tps) secondar y throttle position sensor...
Page 20
Sv650k7/sk7/ak7/sak7 (’07-model) 19 ecm terminal terminal no. Circuit terminal no. Circuit 1 gp switch signal (gp) h — 2 iat sensor signal (iat) i ect sensor signal (ect) 3 iap sensor signal #1 (iap. F) j to sensor signal (tos) 4 stp sensor signal (stp) k tp sensor signal (tp) 5 power source for sen...
Page 21
20 sv650k7/sk7/ak7/sak7 (’07-model) fail-safe function fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. The engine can start and can run even if the above signal is not received...
Page 22
Sv650k7/sk7/ak7/sak7 (’07-model) 21 dtc table and defective condition dtc no. Detected item detected failure condition check for c00 no fault ––––––––––– ––––––––––– c12 (p0335) ckp sensor the signal does not reach ecm for 2 sec. Or more, after receiving the starter signal. Ckp sensor wiring and mec...
Page 23
22 sv650k7/sk7/ak7/sak7 (’07-model) dtc no. Detected item detected failure condition check for c23 (p1651) to sensor the sensor voltage should be the fol- lowing for 2 sec. And more, after igni- tion switch is turned on. 0.2 v in other than the above value, c23 (p1651) is indicated. To sensor, lead ...
Page 24
Sv650k7/sk7/ak7/sak7 (’07-model) 23 dtc no. Detected item detected failure condition check for c32 (p0201)/ c33 (p0202) fuel injector ckp sensor (pickup coil) signal is pro- duced, but fuel injector signal is inter- rupted several times (front 8 times, rear 8 times) or more continuously. In this cas...
Page 25
24 sv650k7/sk7/ak7/sak7 (’07-model) dtc troubleshooting “c12” (p0335) ckp sensor circuit malfunction on model k7, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ecm terminal are located as shown in the illustration. * refer to the sv650/s service...
Page 26
Sv650k7/sk7/ak7/sak7 (’07-model) 25 4) disconnect the iap sensor coupler. 5) turn the ignition switch on. 6) measure the voltage at the red wire 3 and ground. 7) also, measure the voltage at the red wire 3 and b/br wire 4. $ iap sensor input voltage: 4.5 – 5.5 v ( + red – - ground) ( + red – - b/br)...
Page 27
26 sv650k7/sk7/ak7/sak7 (’07-model) step 3 1) turn the ignition switch off. 2) remove the iap sensor. 3) connect the vacuum pump gauge to the vacuum port of the iap sensor. 4) arrange 3 new 1.5 v batteries in series 1 (check that total - voltage is 4.5 – 5.0 v) and connect - terminal to the ground -...
Page 28
Sv650k7/sk7/ak7/sak7 (’07-model) 27 “c14” (p0120-h/l) tp sensor circuit malfunction inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 1) turn the ignition switch off. 2) lift and support the fuel tank with its prop stay. ( #sv650/sk3 5-6) 3) check the tp sensor coupl...
Page 29
28 sv650k7/sk7/ak7/sak7 (’07-model) 6) measure the voltage at the red wire b and ground. 7) also, measure the voltage at the red wire b and b/br wire c. $ tp sensor input voltage: 4.5 – 5.5 v ( + red – - ground) ( + red – - b/br) " 09900-25008: multi-circuit tester set ' tester knob indication: volt...
Page 30
Sv650k7/sk7/ak7/sak7 (’07-model) 29 “c15” (p0115-h/l) ect sensor circuit malfunction on model k7, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ecm terminal are located as shown in the illustration. * refer to the sv650/s service manual 4-31 for...
Page 31
30 sv650k7/sk7/ak7/sak7 (’07-model) 5) measure the voltage between dg wire terminal and ground. 6) also, measure the voltage between dg wire terminal and b/br wire terminal. $ iat sensor input voltage: 4.5 – 5.5 v ( + dg – - ground) ( + dg – - b/br) " 09900-25008: multi-circuit tester set 09900-2500...
Page 32
Sv650k7/sk7/ak7/sak7 (’07-model) 31 “c23” (p1651-h/l) to sensor circuit malfunction on model k7, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ecm terminal are located as shown in the illustration. * refer to the sv650/s service manual 4-35 for ...
Page 33
32 sv650k7/sk7/ak7/sak7 (’07-model) “c28” (p1655) stv actuator circuit malfunction inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 1) turn the ignition switch off. 2) lift and support the fuel tank with its prop stay. ( #sv650/sk3 5-6) 3) check the stva coupler for...
Page 34
Sv650k7/sk7/ak7/sak7 (’07-model) 33 step 2 1) turn the ignition switch off. 2) disconnect the stva coupler and remove the throttle body. ( #page 51) 3) check the continuity between each terminal and ground. $ stva continuity: ∞Ω (infinity) (terminal – ground) 4) if ok, then measure the stva resistan...
Page 35
34 sv650k7/sk7/ak7/sak7 (’07-model) active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “secondary throttle operating control” 1. 4) click each button 2. At this time, if an operation sound is heard from ...
Page 36
Sv650k7/sk7/ak7/sak7 (’07-model) 35 “c29” (p1654-h/l) stp sensor circuit malfunction inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 1) turn the ignition switch off. 2) lift and support the fuel tank with its prop stay. ( #sv650/sk3 5-6) 3) check the stp sensor cou...
Page 37
36 sv650k7/sk7/ak7/sak7 (’07-model) step 2 1) turn the ignition switch off. 2) remove the air cleaner box. ( #page 51) 3) connect the stp sensor coupler. 4) insert the needle pointed probes to the stp sensor coupler. 5) disconnect the stva lead wire coupler. 6) turn the ignition switch on. 7) measur...
Page 38
Sv650k7/sk7/ak7/sak7 (’07-model) 37 “c32” (p0201) or “c33” (p0202) fuel injector circuit malfunction inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 (when indicating c32/p0201 for fuel injector #1) (when indicating c33/p0202 for fuel injector #2) 1) turn the igniti...
Page 39
38 sv650k7/sk7/ak7/sak7 (’07-model) 5) if ok, then check the continuity between each terminal and ground. $ stp sensor continuity: ∞Ω (infinity) " 09900-25008: multi-circuit tester set ) tester knob indication: resistance (Ω) are the resistance and continuity ok? Step 2 1) turn the ignition switch o...
Page 40
Sv650k7/sk7/ak7/sak7 (’07-model) 39 “c40” (p0505 or p0506 and p0507) isc valve circuit malfunction % inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 1) turn the ignition switch off. 2) remove the air cleaner box. ( #page 51) 3) check the isc valve coupler for loose...
Page 41
40 sv650k7/sk7/ak7/sak7 (’07-model) 4) disconnect the isc valve coupler and ecm coupler. 5) check the continuity between terminals a and i, terminals b and 0, terminals c and g, terminals d and \, terminals e and 0, and terminals f and ^. % $ isc valve wire continuity: continuity (*) " 09900-25008: ...
Page 42
Sv650k7/sk7/ak7/sak7 (’07-model) 41 active control inspection (isc rpm control) check 1 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) check that the engine is running. 3) click the “active control”. 4) click the “isc rpm control” 1. 5) check that the “spec” 2 is...
Page 43
42 sv650k7/sk7/ak7/sak7 (’07-model) check 3 1) click the button 1 and increase the “spec” 2 to 1 400 rpm slowly. 2) check that the “desired idle speed” 3 is nearly equal to the “spec” 2. Also, check that the number of steps 4 in the isc valve position increases . Check 4 1) increase the “spec” 1 to ...
Page 44
Sv650k7/sk7/ak7/sak7 (’07-model) 43 “c41” (p0230) fp relay circuit malfunction on model k7, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ecm terminal are located as shown in the illustration. * refer to the sv650/s service manual 4-44 for detai...
Page 45
44 sv650k7/sk7/ak7/sak7 (’07-model) “c44” (p0130/p0135) ho2 sensor (ho2s) circuit malfunction (for e-02, 19, 24, 33) inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 (when indicating c44/p0130:) 1) turn the ignition switch off. 2) remove the right frame side cover. ...
Page 46
Sv650k7/sk7/ak7/sak7 (’07-model) 45 7) remove the front seat. ( #sv650/sk3 7-4) 8) disconnect the ecm coupler. 9) check the continuity between w/g wire a and terminal 6. 10)also, check the continuity between b/br wire b and terminal b. % $ ho2 sensor lead wire continuity: continuity (*) " 09900-2500...
Page 47
46 sv650k7/sk7/ak7/sak7 (’07-model) is the voltage ok? Step 1 (when indicating c44/p0135:) 1) turn the ignition switch off. 2) remove the right frame side cover. ( #sv650/sk3 7-4) 3) check the ho2 sensor for loose or poor contacts. If ok, then measure the ho2 sensor resistance. 4) disconnect the ho2...
Page 48
Sv650k7/sk7/ak7/sak7 (’07-model) 47 step 2 (when indicating c44/p0135:) 1) connect the ho2 sensor coupler. 2) insert the needle pointed probes to the ho2 sensor coupler. 3) turn the ignition switch on and measure the heater voltage between w/b wire and ground. 4) if the tester voltage indicates the ...
Page 49
48 sv650k7/sk7/ak7/sak7 (’07-model) “c49” (p1656) pair control solenoid valve circuit malfunction inspection note: after repairing the trouble, clear the dtc using sds tool. Step 1 1) turn the ignition switch off. 2) check the pair control solenoid valve coupler for loose or poor contacts. If ok, th...
Page 50
Sv650k7/sk7/ak7/sak7 (’07-model) 49 step 2 1) connect the pair control solenoid valve coupler. 2) turn the ignition switch on. 3) insert the needle pointed probes to the pair control solenoid valve coupler. 4) measure the voltage at the wire side coupler between brown wire and ground. $ pair control...
Page 51: Throttle Body
50 sv650k7/sk7/ak7/sak7 (’07-model) throttle body construction only for e-33 1 stp sensor 8 secondary throttle link rod 2 tp sensor 9 throttle link rod 3 o-ring 0 stva & 4 fuel delivery pipe/hose a stp sensor mounting screw item n·m kgf-m lb-ft 5 fuel injector b tp sensor mounting screw a 3.5 0.35 2...
Page 52
Sv650k7/sk7/ak7/sak7 (’07-model) 51 air cleaner and throttle body removal air cleaner box • lift and support the fuel tank with its prop stay. ( #sv650/sk3,5-6) • remove the iap sensor vacuum hoses ( 1, 2). • disconnect the iap sensor (r) coupler 3. • disconnect the iap sensor (f) coupler 4. • disco...
Page 53
52 sv650k7/sk7/ak7/sak7 (’07-model) throttle body • disconnect the fuel hose. • disconnect the various lead wire couplers. 1 tp sensor 2 stp sensor 3 stva • remove the injector lead wire couplers. • disconnect the isc valve hoses. Sa mp le.
Page 54
Sv650k7/sk7/ak7/sak7 (’07-model) 53 • loosen the throttle body clamp screws. • disconnect the throttle cables from their drum. • dismount the throttle body assembly. % * be careful not to damage the throttle cable bracket and fast idle lever when dismounting or remounting the throttle body assembly....
Page 55
54 sv650k7/sk7/ak7/sak7 (’07-model) throttle body disassembly % • remove the clamp. • remove the vacuum hoses ( 1, 2). • disconnect the fuel feed hose 3. • remove the throttle link rod 4 and secondary throttle link rod 5. Note: the throttle link rod 4 is longer than the secondary throttle link rod 5...
Page 56
Sv650k7/sk7/ak7/sak7 (’07-model) 55 • remove the tp sensor 7 and stp sensor 8 with the special tool. " 09930-11950: torx wrench note: prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation. % % % never remove the stva 9 and throttle body link pl...
Page 57
56 sv650k7/sk7/ak7/sak7 (’07-model) throttle body cleaning ! • clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air. % inspection check following items for any damage or clogging. * o-ring * throttle valve * secondary throttle valve * vacuum hose * delivery pip...
Page 58
Sv650k7/sk7/ak7/sak7 (’07-model) 57 throttle body reassembly reassemble the throttle body in the reverse order of disassem- bly. Pay attention to the following points: • with the stv fully closed, install the stp sensor 1 and tighten the stp sensor mounting screw to the specified torque. Note: * app...
Page 59
58 sv650k7/sk7/ak7/sak7 (’07-model) • apply thin coat of the engine oil to the new cushion seal 3, and the o-ring 4. % • install the fuel injector 5 by pushing it straight to the delivery pipe 6. Note: align the coupler e of injector with boss f of the delivery pipe. % • install the fuel delivery pi...
Page 60
Sv650k7/sk7/ak7/sak7 (’07-model) 59 air cleaner box and throttle body installation installation is in the reverse order of removal. Pay attention to the following points: • connect the throttle pulling cable 1 and throttle returning cable 2 to the throttle cable drum. • loosen each throttle cable lo...
Page 61
60 sv650k7/sk7/ak7/sak7 (’07-model) stp sensor adjustment if the stp sensor adjustment is necessary, measure the sensor out put voltage and adjust the stp sensor position as follows: • remove the air cleaner box. ( #page 51) • disconnect the stva coupler. ( #page 28) • insert the needle pointed prob...
Page 62
Sv650k7/sk7/ak7/sak7 (’07-model) 61 tp sensor adjustment after all adjustments are completed, check or adjust the tps setting condition. 1. Warm up the engine and check the engine idle r/min. 2. Remove the right frame side cover. ( #sv650/sk3 7-4) 3. Connect the special tool (mode select switch) to ...
Page 63
62 sv650k7/sk7/ak7/sak7 (’07-model) throttle valve synchronization use of sds tool check and adjust the throttle valve synchronization between two cylinders. Step 1 • lift and support the fuel tank with its prop stay. ( #sv650/sk3 5-6) • remove the rubber caps 1 from each vacuum nipple on the thrott...
Page 64
Sv650k7/sk7/ak7/sak7 (’07-model) 63 • click “active control”. • click “isc air volume control” 3. • click “on” bottom 4 to fix the isc air volume between two cylinders. Note: when making this synchronization, be sure that the water tem- perature is within 80 – 100 °c (176 – 212 °f). A engine speed: ...
Page 65
64 sv650k7/sk7/ak7/sak7 (’07-model) isc valve removal • remove the air cleaner box. ( #page 51) • disconnect the isc valve coupler 1. % • disconnect the hoses and remove the isc valve 2. Installation install the isc valve in the reverse order of removal. Note: when the isc valve is removed or replac...
Page 66
Sv650k7/sk7/ak7/sak7 (’07-model) 65 isc valve pre-set when removing or replace the isc valve, set the isc valve to the following procedures: procedure 1) turn the ignition switch off position. 2) remove the seat. ( #sv650/sk3 7-4) 3) connect the special tool to the dealer mode coupler and turn its s...
Page 67: Ignition System
66 sv650k7/sk7/ak7/sak7 (’07-model) ignition system inspection ignition coil primary peak voltage • disconnect all the spark plug caps. ( #page 13) • connect new spark plugs to each spark plug cap and ground them on the cylinder. Note: be sure that all the spark plugs are connected properly and the ...
Page 68
Sv650k7/sk7/ak7/sak7 (’07-model) 67 • shift the transmission into neutral, turn the ignition switch to the “on” position and grasp the clutch lever. • press the starter button and allow the engine to crank for a few seconds, and then measure the ignition coil primary peak voltage. • repeat the above...
Page 69
68 sv650k7/sk7/ak7/sak7 (’07-model) introduction of abs (for sv650a/sa) front and rear wheel speed sensors wheel speed sensor consists of wheel speed sensor 1 and sensor rotor 2. Abs control unit the abs control unit is located under the battery. Abs control unit calculates signals input from each o...
Page 70
Sv650k7/sk7/ak7/sak7 (’07-model) 69 abs control unit calculating process the abs controls and its calculations, in addition to the self-diagnosing and the fail-safe processes, occur during the abs control unit calculating process. In addition, if a malfunction is detected by the self-diagnosis funct...
Page 71
70 sv650k7/sk7/ak7/sak7 (’07-model) hydraulic unit (hu) the hydraulic unit operates the solenoid valves based upon the signal which is output from the abs control unit. The brake fluid pressure is then adjusted accordingly. The hydraulic unit controls the front and rear brake systems individually by...
Page 72
Sv650k7/sk7/ak7/sak7 (’07-model) 71 fail-safe function if malfunction occurs in the abs electric system, this sets valve relay off. Consequently, motor relay will be set off and the indicator light on, and no current will be applied to motor solenoid valve inactivating abs and turning abs indicator ...
Page 73: Cautions In Servicing
72 sv650k7/sk7/ak7/sak7 (’07-model) cautions in servicing abs wiring • the abs parts are connected to various lead wires. The cou- pler and lead wire connections, as well as the lead wire and wire harness routing must be done correctly. Make sure that the proper clamps are used and positioned correc...
Page 74
Sv650k7/sk7/ak7/sak7 (’07-model) 73 battery • only use a fully charged battery. • in order to prevent damage to the abs control unit etc., be sure to connect the battery properly. • never disconnect the battery or any other lead wires while the engine is running. Note: for battery and battery connec...
Page 75
74 sv650k7/sk7/ak7/sak7 (’07-model) abs information ! • be sure to route the brake hoses correctly. • the abs does not shorten the motorcycle’s braking distance. When riding down slopes or on wet or bumpy roads the braking distance is lengthened as compared to a motorcycle without abs. In addition, ...
Page 76: Abs Components
Sv650k7/sk7/ak7/sak7 (’07-model) 75 abs components abs components location 1 abs indicator light 4 abs control unit/hu 2 front wheel speed sensor rotor 5 rear wheel speed sensor rotor 3 front wheel speed sensor 6 rear wheel speed sensor sa mp le.
Page 77
76 sv650k7/sk7/ak7/sak7 (’07-model) abs coupler connection diagram b/w o r r/b b/w b/r w/y gr/r bl w/r o/y b/y abs contr ol unit sds coupler o/g gr/r w/r b/w abs mo t or fuse 40a sp are 40a abs v a lve fuse 25a sp are 25a speedometer bl/b b/w b/g p/w lg b/lg y g/y r/b br/b o/r o/g r/w b y fr ont whe...
Page 78
Sv650k7/sk7/ak7/sak7 (’07-model) 77 abs wiring diagram r o b/r o o b/y o/y w/r bl gr/r w/y b/r b/w r/b r b/w b/w b/w b/y w/y b/r w/r b w b w o b/w bi o/g o/y o/g r r/b on off lock p ignition switch battery abs fws rws abs valve fuse (25 a) abs motor fuse (40 a) abs control unit mode select coupler s...
Page 79
78 sv650k7/sk7/ak7/sak7 (’07-model) abs unit system diagram pump motor motor rela y va lv e rela y rear wheel speed sensor f ront wheel speed sensor abs indicator light 25 11 16 5 7 19 4 13 2 12 18 43 2 1 15 14 13 12 11 10 9 8 7 6 5 26 25 24 23 22 21 20 19 18 17 16 f ront inlet v alv e f ront outlet...
Page 80: Abs Troubleshooting
Sv650k7/sk7/ak7/sak7 (’07-model) 79 abs troubleshooting abs troubleshooting description many of the abs malfunction diagnosing operations are performed by checking the wiring continuity. Quick and accurate detection of malfunctions within the complex circuitry assures the proper operation of the abs...
Page 81
80 sv650k7/sk7/ak7/sak7 (’07-model) troubleshooting procedure troubleshooting should be proceed as follows. If the order is performed incorrectly or any part is omitted, a misdiagnosis may result. 1. Gather information from the customer. ( #page 82) 2. Perform the pre-diagnosis inspection. ( #page 8...
Page 82
Sv650k7/sk7/ak7/sak7 (’07-model) 81 basic troubleshooting diagram 1. Gather information from the customer. ( "page 82) 2. Perform the pre-diagnosis inspection. ( "page 83) 3. Inspect the abs indicator light. ( "page 86) 6. Inspect the abs components. ( "page 119) 4. Output the dtcs stored in the abs...
Page 83
82 sv650k7/sk7/ak7/sak7 (’07-model) information gathering to properly diagnose a malfunction, one must not make guesses or assumptions about the circumstances that caused it. Proper diagnosis and repair require duplicating the situation in which the malfunction occurred. If a diagnosis is made witho...
Page 84
Sv650k7/sk7/ak7/sak7 (’07-model) 83 pre-diagnosis inspection the mechanical and hydraulic components of the brake system should be inspected prior to performing any electrical checks. These inspections may find problems that the abs could not detect; thus, shortening repair time. Brake brake fluid l...
Page 85
84 sv650k7/sk7/ak7/sak7 (’07-model) abs component wheel speed sensor – sensor rotor clearance • inspect the clearance between the wheel speed sensor and sensor rotor for each wheel using the thickness gauge. $ wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) " 09900-20803...
Page 86
Sv650k7/sk7/ak7/sak7 (’07-model) 85 • lift up the battery case 2 and disconnect the abs control unit coupler 3. • check for continuity between 1 terminal of coupler and bat- tery - terminal, also 4 terminal of coupler and battery - ter- minal. " 09900-25008: multi-circuit tester set + tester knob in...
Page 87
86 sv650k7/sk7/ak7/sak7 (’07-model) abs indicator light inspection step 1 1) check if the abs indicator light lights up when turning the ignition switch to on. Note: if the abs indicator light flashes, there may be a short-circuit existing in the mode select switch wire. Does the abs indicator light...
Page 88
Sv650k7/sk7/ak7/sak7 (’07-model) 87 step 4 1) disconnect the abs control unit coupler. ( #page 85) 2) turn the ignition switch to on with the abs control unit cou- pler disconnected, measure the voltage between b terminal and 4 terminal at the coupler. $ normal value: 7.5 – 9.5 v and more " 09900-25...
Page 89
88 sv650k7/sk7/ak7/sak7 (’07-model) step 7 1) disconnect the abs control unit coupler. ( #page 85) 2) turn the ignition switch to on with the abs control unit cou- pler disconnected, measure the voltage between h terminal and 4 terminal at the coupler. $ normal value: battery voltage (12.0 v and mor...
Page 90
Sv650k7/sk7/ak7/sak7 (’07-model) 89 dtc (diagnostic trouble code) output connect the special tool to the mode select coupler to output the memorized dtcs on the abs indicator light. • turn the ignition switch to off. • remove the front seat. ( #sv650/sk3 7-4) • connect the special tool to the mode s...
Page 91
90 sv650k7/sk7/ak7/sak7 (’07-model) understanding the dtc (diagnostic trouble code) a two-digit dtc is shown through the flashing pattern of the abs indicator light. A number between 1 and 9 is represented by the number of times that the abs indicator light lights up in interval of 0.4 seconds and t...
Page 92
Sv650k7/sk7/ak7/sak7 (’07-model) 91 dtc deleting and abs operation check dtc deleting • connect the special tool to the mode select coupler (orange – b/w) and output the dtcs. " 09930-82710: mode select switch • while the dtcs are being output, set the special tool to off. % • in the dtc deletion mo...
Page 93
92 sv650k7/sk7/ak7/sak7 (’07-model) abs operation check after deleting the dtcs, repeat the code output procedure and make sure that no dtcs remain (the abs indicator light no longer flashes). If any dtcs remain, perform the appropriate procedures, then delete the codes. If dtcs are left stored, con...
Page 94
Sv650k7/sk7/ak7/sak7 (’07-model) 93 sds check using sds, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they...
Page 95
94 sv650k7/sk7/ak7/sak7 (’07-model) use of sds diagnostic procedures * don’t disconnect couplers from abs hu, the battery cable from the battery, abs hu ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disco...
Page 96
Sv650k7/sk7/ak7/sak7 (’07-model) 95 use of sds diagnosis reset procedure • after repairing the trouble, turn off the ignition switch and turn on again. • click the abs button 1. • click the “dtc inspection” button 2. • check the dtc. • the previous malfunction history code (past dtc) still remains s...
Page 97
96 sv650k7/sk7/ak7/sak7 (’07-model) • follow the displayed instructions. • check that both “current dtc” 4 and “past dtc” 5 are deleted (nil). Sa mp le.
Page 98
Sv650k7/sk7/ak7/sak7 (’07-model) 97 active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “abs” 1. 4) click “active control” 2. 5) click “abs hu operating” 3. Sa mp le.
Page 99
98 sv650k7/sk7/ak7/sak7 (’07-model) 6) it progresses to the next according to the following indication of screens. Note: skip this screen as this vehicle is not equipped with parking brake. Return next cancel help return next cancel help sa mp le.
Page 100
Sv650k7/sk7/ak7/sak7 (’07-model) 99 note: * if the front wheel is selected, lift the front wheel off the ground using a jack. * two operators are needed in this work; one should apply a rotational force to the front wheel. Return next cancel help return next cancel help sa mp le.
Page 101
100 sv650k7/sk7/ak7/sak7 (’07-model) note: * in normal cases, the front brake lever feels a reaction force and the front wheel turns discontinuously. At the same time, the abs hu operating sound will be heard. * the abs hu motor operates for 6 seconds and then stops automatically. Note: * inspect th...
Page 102
Sv650k7/sk7/ak7/sak7 (’07-model) 101 dtc table of abs *1 it goes off after running at more than 5 km/h (3.1 mile/h). *2 the wheel speed sensor lead wire is connected to the abs control unit, but a short-circuit or faulty conti- nuity inside the abs control unit caused this dtc to appear, therefore, ...
Page 103
102 sv650k7/sk7/ak7/sak7 (’07-model) dtc troubleshooting dtc “25” (c1625): wheel speed sensor related malfunction step 1 1) check that the specified tires are installed. Tire type: front: dunlop d220fst 120/60zr17m/c 55w (sv650a) : dunlop d220fst m 120/60zr17m/c 55w (sv650sa) rear: dunlop d220st l 1...
Page 104
Sv650k7/sk7/ak7/sak7 (’07-model) 103 step 4 1) inspect the clearances of the front and rear wheel speed sen- sor – sensor rotor using the thickness gauge. $ wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) " 09900-20803: thickness gauge 09900-20806: thickness gauge are th...
Page 105
104 sv650k7/sk7/ak7/sak7 (’07-model) dtc “35” (c1635): abs motor malfunction step 1 1) inspect if the pump motor makes turning noise by setting the ignition switch to on from off when the vehicle stands still. Does the pump motor make any turning noise? Step 2 1) remove the front seat. ( #sv650/sk3 ...
Page 106
Sv650k7/sk7/ak7/sak7 (’07-model) 105 dtc “41” (c1641): wheel speed sensor signal malfunction (f) step 1 1) inspect the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge. $ wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) " 09900-208...
Page 107
106 sv650k7/sk7/ak7/sak7 (’07-model) dtc “42” (c1642): wheel speed sensor circuit open (f) step 1 1) turn the ignition switch to off. 2) remove the abs control unit/hu cover. ( #page 84) 3) remove the headlight. (sv650a) ( #sv650/sk3 8-37) 4) check the abs control unit coupler and front wheel speed ...
Page 108
Sv650k7/sk7/ak7/sak7 (’07-model) 107 step 4 1) measure the resistance between 5 terminal and ground at the abs control unit coupler. $ normal value: ∞ Ω (infinity) ) tester knob indication: resistance (Ω) is the resistance between 5 and ground ok? Step 5 1) measure the resistance between 1 terminal ...
Page 109
108 sv650k7/sk7/ak7/sak7 (’07-model) step 8 1) connect the front wheel speed sensor coupler. 2) connect three 1.5 v dry cells a in series as shown and make sure that their total voltage is more than 4.5 v. Measure the current between + dry cell terminal and f ter- minal on the abs control unit coupl...
Page 110
Sv650k7/sk7/ak7/sak7 (’07-model) 109 dtc “44” (c1644): wheel speed sensor signal malfunction (r) step 1 1) inspect the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge. $ wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) " 09900-2080...
Page 111
110 sv650k7/sk7/ak7/sak7 (’07-model) dtc “45” (c1645): wheel speed sensor circuit open (r) step 1 1) turn the ignition switch to off. 2) remove the abs control unit/hu cover. ( #page 84) 3) check the abs control unit coupler and rear wheel speed sensor coupler for loose or poor contacts. If ok, then...
Page 112
Sv650k7/sk7/ak7/sak7 (’07-model) 111 step 4 1) measure the resistance between i terminal and ground at the abs control unit coupler. $ normal value: ∞Ω (infinity) ) tester knob indication: resistance (Ω) is the resistance between i and ground ok? Step 5 1) measure the resistance between 1 terminal a...
Page 113
112 sv650k7/sk7/ak7/sak7 (’07-model) step 8 1) connect the rear wheel speed sensor coupler. 2) connect three 1.5 v dry cells a in series as shown and make sure that their total voltage is more than 4.5 v. Measure the current between + dry cell terminal and 7 ter- minal on the abs control unit couple...
Page 114
Sv650k7/sk7/ak7/sak7 (’07-model) 113 dtc “47” (c1647): supply voltage (increased) note: when the voltage resumes the normal level, the abs indicator light will go off. Step 1 1) turn the ignition switch to off. 2) remove the front seat. ( #sv650/sk3 7-4) 3) measure the voltage between the + and - ba...
Page 115
114 sv650k7/sk7/ak7/sak7 (’07-model) step 3 1) turn the ignition switch to off. 2) remove the abs control unit/hu cover. ( #page 84) 3) check the abs control unit coupler for loose or poor con- tacts. If ok, then disconnect the abs control unit coupler. ( #page 85) 4) run the engine at 5 000 r/min w...
Page 116
Sv650k7/sk7/ak7/sak7 (’07-model) 115 dtc “48” (c1648): supply voltage (decreased) note: when the voltage resumes the normal level, the abs indicator light will go off. Step 1 1) turn the ignition switch to off. 2) remove the front seat. ( #sv650/sk3 7-4) 3) measure the voltage between the + and - ba...
Page 117
116 sv650k7/sk7/ak7/sak7 (’07-model) step 3 1) turn the ignition switch to off. 2) remove the abs control unit/hu cover. ( #page 84) 3) check the abs control unit coupler for loose or poor con- tacts. If ok, then disconnect the abs control unit coupler. ( #page 85) 4) run the engine at 5 000 r/min w...
Page 118
Sv650k7/sk7/ak7/sak7 (’07-model) 117 dtc “55” (c1655): abs control unit malfunction step 1 1) inspect the clearances of the front and rear wheel speed sen- sor – sensor rotor using the thickness gauge. $ wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) " 09900-20803: thic...
Page 119
118 sv650k7/sk7/ak7/sak7 (’07-model) dtc “61” (c1661): abs solenoid malfunction step 1 1) turn the ignition switch to off. 2) remove the front seat. ( #sv650/sk3 7-4) 3) open the fuse box and inspect the abs valve fuse. Abs valve fuse: 25 a is the abs valve fuse ok? % step 2 1) remove the abs contro...
Page 120
Sv650k7/sk7/ak7/sak7 (’07-model) 119 abs component removal, inspection and installation front wheel speed sensor/sensor rotor removal % • remove the front wheel speed sensor 1 by removing the mounting bolt. • remove the front wheel assembly. ( #sv650/sk3 7-9) ! • remove the front wheel speed sensor ...
Page 121
120 sv650k7/sk7/ak7/sak7 (’07-model) • remove the headlight. (sv650a) ( #sv650/sk3 8-37) • disconnect the sensor coupler 4 and remove the front wheel speed sensor. ( #page 142 and 143) inspection • inspect the wheel speed sensor for damage. • clean the sensor if any metal particle or foreign materia...
Page 122
Sv650k7/sk7/ak7/sak7 (’07-model) 121 • install the front wheel assembly. ( #sv650/sk3 7-15) • align the recess a on the speed sensor bracket with the stop- per b on the right front fork. • check the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge. $ wheel sp...
Page 123
122 sv650k7/sk7/ak7/sak7 (’07-model) front wheel speed sensor installation left right 0.3 – 1.5 mm (0.012 – 0.059 in) front wheel speed sensor sa mp le.
Page 124
Sv650k7/sk7/ak7/sak7 (’07-model) 123 rear wheel speed sensor/sensor rotor removal % • remove the rear wheel speed sensor 1 by removing the mounting bolt. • remove the rear wheel assembly. ( #sv650/sk3 7-42) ! • remove the rear wheel speed sensor rotor 2. % • remove the battery case. ( #page 126) • d...
Page 125
124 sv650k7/sk7/ak7/sak7 (’07-model) inspection • inspect the wheel speed sensor for damage. • clean the sensor if any metal particle or foreign material stuck on it. • check that no wheel speed sensor rotor teeth are broken and that no foreign objects are caught in the wheel speed sensor. Installat...
Page 126
Sv650k7/sk7/ak7/sak7 (’07-model) 125 rear wheel speed sensor installation right left 0.3 – 1.5 mm (0.012 – 0.059 in) rear wheel speed sensor for e-03, 28, 33 sa mp le.
Page 127
126 sv650k7/sk7/ak7/sak7 (’07-model) abs control unit/hu removal ! % • remove the front seat. ( #sv650/sk3 7-4) • remove the battery. • disconnect the following parts from the battery case 1. 2 fuse box 3 starter relay 4 fuel pump relay 5 abs motor relay fuse 6 abs valve relay fuse 7 rubber seat • r...
Page 128
Sv650k7/sk7/ak7/sak7 (’07-model) 127 • remove the abs control unit/hu cover a. • drain the brake fluid. ( #sv650/sk3 7-65) • loosen the flare nuts b and disconnect the brake pipes. • disconnect the abs control unit coupler c. • remove the abs control unit/hu by removing the mounting bolts d. Pull up...
Page 129
128 sv650k7/sk7/ak7/sak7 (’07-model) installation installation is in the reverse order of removal. Pay attention to the following points. • tighten the brake pipe flare nuts 1 to the specified torque. & brake pipe flare nut: 16 n·m (1.6 kgf-m, 11.5 lb-ft) % • bleed air from the brake fluid circuit. ...
Page 130: Installation
Sv650k7/sk7/ak7/sak7 (’07-model) 129 wiring harness, cable, hose routing and sensor installation wiring harness routing (for sv650/s) 1 throttle cable *3 to fan motor. 2 isc valve coupler *4 clamp harness without contact to bracket. 3 clutch cable *5 be careful for the lead wire not to be slackened....
Page 131
130 sv650k7/sk7/ak7/sak7 (’07-model) upper upper turn signal l & r speed sensor wiring harness magneto lead side-stand switch gp switch magneto ices label (e-28 only) clamp clamp 10 mm (0.4 in) set “ ” mark exhaust side set the seal of plug cap firmly. (ex) (ex) (in) (in) (ex) (ex) (in) (in) clamp l...
Page 132
Sv650k7/sk7/ak7/sak7 (’07-model) 131 wire harness routing (for sv650a/sa) 1 throttle cable 8 rectifier 2 isc valve coupler 9 clamp 3 clutch cable *1 to fan motor 4 abs control unit *2 clamp harness without contact to bracket. 5 brake pipe (abs) *3 base for assembling (white tape) tps branch wire : s...
Page 133
132 sv650k7/sk7/ak7/sak7 (’07-model) upper upper turn signal l & r speed sensor wiring harness wiring harness magneto lead starter motor side-stand switch gp switch magneto ices label (e-28 only) clamp clamp 10 m m (0.4 in) set “ ” mark exhaust side set the seal of plug cap firmly. (ex) (ex) (in) (i...
Page 134
Sv650k7/sk7/ak7/sak7 (’07-model) 133 cable routing (for sv650/a) 1 throttle cable no.1 5 wiring harness 2 throttle cable no.2 6 handle switch (l) 3 clutch cable 7 brake hose (for sv650a) 4 guide 0 mm (0 in) 0 m m (0 in) 0 mm (0 in) 0 m m (0 in ) sa mp le.
Page 135
134 sv650k7/sk7/ak7/sak7 (’07-model) cable routing (for sv650s/sa) 1 throttle cable no.1 5 wiring harness 2 throttle cable no.2 6 handle switch (l) 3 clutch cable 7 brake hose (for sv650sa) 4 guide 8 speed sensor (for sv650s) 0 mm (0 in) 0 m m (0 in) 0 mm (0 in) 0 m m (0 in ) sa mp le.
Page 136
Sv650k7/sk7/ak7/sak7 (’07-model) 135 front brake hose routing (for sv650) 14 ˚ *2 *1 35 ˚ a view a view b *1 *3 *4 *5 *4 14 ˚ c d b view c view d 14 ˚ 1 stopper *2 after positioning the brake hose junction with the stopper, tighten the bolt. 2 front brake hose *3 after positioning the clamp with the...
Page 137
136 sv650k7/sk7/ak7/sak7 (’07-model) front brake hose routing (for sv650a) *1 *5 *7 *6 14˚ 35 ˚ 42˚ 42˚ 42˚ 42˚ 14˚ 14˚ *3 *2 *9 *11 *11 *13 *12 *10 *4 *8 1 abs control unit/hu *7 pass through the throttle cables in front of the brake hose. 2 clamp *8 pass through the brake pipes inside of the fuel ...
Page 138
Sv650k7/sk7/ak7/sak7 (’07-model) 137 front brake hose routing (for sv650sa) 1 abs control unit/hu *8 clamp ends should face backward. 2 clamp *9 clamp ends should face forward. *1 pass through the brake hose a under the b. *10 pass through the brake pipes inside of the fuel tank drain hose and breat...
Page 139
138 sv650k7/sk7/ak7/sak7 (’07-model) rear brake hose routing (for sv650/s) 1 brake hose *3 no contact with reservoir tank and seat rail. 2 brake hose guide *4 after the brake hose union has contacted the stopper, tighten the union bolt. 3 stopper *5 white paint *1 after positioning the bracket with ...
Page 140
Sv650k7/sk7/ak7/sak7 (’07-model) 139 rear brake hose routing (for sv650a/sa) 1 guide *4 white paint 2 wheel speed sensor lead *5 clamp sleeve of brake hose to guide. 3 screw *6 no contact with reservoir tank and seat rail. 4 washer *7 clamp sleeve of brake hose. 5 brake hose *8 after the brake hose ...
Page 141
140 sv650k7/sk7/ak7/sak7 (’07-model) cooling system hose routing *1 clamp bolt head must face downward. *7 clamp ends should face forward. *2 clamp bolt head must face left side. *8 marking mark (white) *3 clamp ends should face downward. *9 matching mark (yellow) *4 clamp ends should face upward. *...
Page 142
Sv650k7/sk7/ak7/sak7 (’07-model) 141 1 reservoir tank 9 oil filter 2 reservoir tank over flow hose 0 water pump drain hose 3 fuel tank breather hose *1 the clamp bolt head must face downward. 4 thermostat *2 matching mark (yellow) 5 reservoir tank inlet hose *3 matching mark (white) 6 fuel tank brea...
Page 143
142 sv650k7/sk7/ak7/sak7 (’07-model) pair (air supply) system hose routing 1 air cleaner *2 matching mark (yellow) 2 fuel hose *3 be careful not to touch the air cleaner and fuel hose. 3 pair valve *4 pass through the hose between head cover and intake pipe. *1 matching mark (white) *4 *2 *1 *3 *1 a...
Page 144
Sv650k7/sk7/ak7/sak7 (’07-model) 143 front wheel speed sensor installation (for sv650a) *1 pass the wheel speed sensor lead wire and speed sensor lead wire in front of the brake hose. *7 into headlight housing *2 clamp the sensor lead wire to brake hose with speed sensor lead wire at yellow marking....
Page 145
144 sv650k7/sk7/ak7/sak7 (’07-model) front wheel speed sensor installation (for sv650sa) *1 clamp the sensor lead wire to wiring harness with speed sensor lead wire at yellow marking. *6 clamp the sensor lead wire to brake hose at sleeve. *2 pass the wheel speed sensor lead wire and speed sensor lea...
Page 146
Sv650k7/sk7/ak7/sak7 (’07-model) 145 rear wheel speed sensor installation (for sv650a/sa) 1 guide 7 wheel speed sensor 2 brake hose *1 check the clearance between clamp and swin- garm. 3 wheel speed sensor lead wire *2 cut excess tip. 4 washer *3 clamp the sensor lead wire at white painted line. 5 s...
Page 147: Throttle Body Installation
146 sv650k7/sk7/ak7/sak7 (’07-model) throttle body installation 1 pair valve hose (f) *7 matching mark (white) 2 isc valve hose (r) *8 match mark to bulge of nipple. 3 isc valve hose *9 be careful not touch the throttle body. 4 pair valve hose *10 cut after clamping. *1 clamp ends should face back s...
Page 148: Rear Fender Installation
Sv650k7/sk7/ak7/sak7 (’07-model) 147 rear fender installation 1 battery holder 4 rear rear fender 2 seat rail 5 front rear fender 3 clamp sa mp le.
Page 149: Heat Shield Installation
148 sv650k7/sk7/ak7/sak7 (’07-model) heat shield installation 1 sheet bracket 4 battery holder 2 heat shield rubber sheet 5 abs control unit/hu holder 3 abs control unit/hu *1 set both side to rear fender front firmly. *1 sa mp le.
Page 150: Ignition Coil Installation
Sv650k7/sk7/ak7/sak7 (’07-model) 149 ignition coil installation 1 frame 2 front ignition coil 3 rear ignition coil fwd sa mp le.
Page 151: Emission Control System
150 sv650k7/sk7/ak7/sak7 (’07-model) emission control system exhaust emission control system (pair system) the exhaust emission control system is composed of the pair system and catalyst system. The fresh air is drawn into the exhaust port with the pair solenoid valve and pair reed valve. The pair s...
Page 152: (For E-02, 19, 24, 33)
Sv650k7/sk7/ak7/sak7 (’07-model) 151 pair (air supply) system inspection hoses #sv650/sk3 10-6 pair reed valve #sv650/sk3 10-6 pair control solenoid valve #page 48 heated oxygen sensor (ho2s) inspection (for e-02, 19, 24, 33) #page 44 sa mp le.
Page 153: Special Tools
152 sv650k7/sk7/ak7/sak7 (’07-model) special tools note: when order the special tool, please confirm whether it is available or not. Tightening torque 09900-20803 09900-20806 thickness gauge 09900-25008 multi-circuit tester set 09900-25009 needle pointed probe set 09900-28630 tps test wire har- ness...
Page 154: Service Data (Sv650/s)
Sv650k7/sk7/ak7/sak7 (’07-model) 153 service data (sv650/s) valve + guide unit: mm (in) item standard limit valve diam. In. 31 (1.2) ---- ex. 25.5 (1.0) ---- valve clearance (when cold) in. 0.1 – 0.2 (0.004 – 0.008) ---- ex. 0.2 – 0.3 (0.008 – 0.012) ---- valve guide to valve stem clearance in. 0.02...
Page 155
154 sv650k7/sk7/ak7/sak7 (’07-model) camshaft + cylinder head unit: mm (in) item standard limit cam height in. 36.060 – 36.105 (1.4196 – 1.4214) 35.76 (1.408) ex. 34.680 – 34.725 (1.3654 – 1.3671) 34.38 (1.354) camshaft journal oil clearance in. & ex. 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0059) c...
Page 156
Sv650k7/sk7/ak7/sak7 (’07-model) 155 cylinder + piston + piston ring unit: mm (in) item standard limit compression pressure 1 500 kpa (15 kgf/cm 2 , 213 psi) 1 100 kpa (11 kgf/cm 2 , 156 psi) compression pressure difference ---- 200 kpa (2 kgf/cm 2 , 28 psi) piston to cylinder clearance 0.055 – 0.06...
Page 157
156 sv650k7/sk7/ak7/sak7 (’07-model) conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit conrod small end i.D. 20.010 – 20.018 (0.7878 – 0.7881) 20.040 (0.7890) conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) 0.5 (0.02) conrod big end width 20.95 – 21.00...
Page 158
Sv650k7/sk7/ak7/sak7 (’07-model) 157 transmission + drive chain unit: mm (in) except ratio item standard limit primary reduction ratio 2.088 (71/34) ---- final reduction ratio sv650 3.000 (45/15) ---- sv650s * 3.000 (45/15) ---- gear ratios low 2.461 (32/13) ---- 2nd 1.777 (32/18) ---- 3rd 1.380 (29...
Page 159
158 sv650k7/sk7/ak7/sak7 (’07-model) thermostat + radiator + fan + coolant injector + fuel pump + fuel pressure regulator item standard note thermostat valve opening temperature * approx. 76.5 °c (170 °f) ---- thermostat valve lift * over 8.0 mm (0.31 in) at 90 °c (194 °f) ---- engine coolant temper...
Page 160
Sv650k7/sk7/ak7/sak7 (’07-model) 159 fi sensors throttle body item specification note ckp sensor resistance 130 – 240 Ω ckp sensor peak voltage 3.7 v (when cranking) and more iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage * approx. 2.5 v at idle speed tp sensor input voltage 4.5 – 5....
Page 161
160 sv650k7/sk7/ak7/sak7 (’07-model) electrical unit: mm (in) item specification note firing order 1.2 spark plug type ngk: cr8e denso: u24esr-n gap 0.7 – 0.8 mm (0.028 – 0.031 in) spark performance over 8 mm (0.3 in) at 1 atm. Crankshaft position sensor resistance 130 – 240 Ω bi – g ignition coil r...
Page 162
Sv650k7/sk7/ak7/sak7 (’07-model) 161 wattage unit: w item specification sv650s sv650 e-03, 24, 28, 33 others headlight hi 60 × 2 60 ← lo 55 × 2 55 ← parking or position light 5 × 2 5 brake light/taillight led ← ← turn signal light 21 ← ← license light 5 ← ← speedometer light led ← ← tachometer light...
Page 163
162 sv650k7/sk7/ak7/sak7 (’07-model) brake + wheel unit: mm (in) item standard limit rear brake pedal height sv650 50 – 60 (1.97 – 2.36) ---- sv650s 60 – 70 (2.36 – 2.76) brake disc thickness front 4.5 (0.18) 4.0 (0.16) rear 5.0 (0.20) 4.5 (0.18) brake disc runout ---- 0.3 (0.012) master cylinder bo...
Page 164
Sv650k7/sk7/ak7/sak7 (’07-model) 163 tire suspension unit: mm (in) item std/spec. Limit cold inflation tire pressure (solo riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 250 kpa (2.50 kgf/cm², 36 psi) ---- cold inflation tire pressure (dual riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- r...
Page 165
164 sv650k7/sk7/ak7/sak7 (’07-model) fuel + oil item std/spec. Note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10% ethanol, or less than 5% methanol...
Page 166: Service Data (Sv650A/sa)
Sv650k7/sk7/ak7/sak7 (’07-model) 165 service data (sv650a/sa) valve + guide unit: mm (in) item standard limit valve diam. In. 31 (1.2) ---- ex. 25.5 (1.0) ---- valve clearance (when cold) in. 0.1 – 0.2 (0.004 – 0.008) ---- ex. 0.2 – 0.3 (0.008 – 0.012) ---- valve guide to valve stem clearance in. 0....
Page 167
166 sv650k7/sk7/ak7/sak7 (’07-model) camshaft + cylinder head unit: mm (in) item standard limit cam height in. 36.060 – 36.105 (1.4196 – 1.4214) 35.76 (1.408) ex. 34.680 – 34.725 (1.3654 – 1.3671) 34.38 (1.354) camshaft journal oil clearance in. & ex. 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0059) c...
Page 168
Sv650k7/sk7/ak7/sak7 (’07-model) 167 cylinder + piston + piston ring unit: mm (in) item standard limit compression pressure 1 500 kpa (15 kgf/cm 2 , 213 psi) 1 100 kpa (11 kgf/cm 2 , 156 psi) compression pressure difference ---- 200 kpa (2 kgf/cm 2 , 28 psi) piston to cylinder clearance 0.055 – 0.06...
Page 169
168 sv650k7/sk7/ak7/sak7 (’07-model) conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit conrod small end i.D. 20.010 – 20.018 (0.7878 – 0.7881) 20.040 (0.7890) conrod big end side clearance 0.170 – 0.320 (0.0067 – 0.0126) 0.5 (0.02) conrod big end width 20.95 – 21.00...
Page 170
Sv650k7/sk7/ak7/sak7 (’07-model) 169 transmission + drive chain unit: mm (in) except ratio item standard limit primary reduction ratio 2.088 (71/34) ---- final reduction ratio sv650a 3.000 (45/15) ---- sv650sa 3.000 (45/15) ---- gear ratios low 2.461 (32/13) ---- 2nd 1.777 (32/18) ---- 3rd 1.380 (29...
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170 sv650k7/sk7/ak7/sak7 (’07-model) thermostat + radiator + fan + coolant injector + fuel pump + fuel pressure regulator item standard note thermostat valve opening temperature approx. 76.5 °c (170 °f) ---- thermostat valve lift over 8.0 mm (0.31 in) at 90 °c (194 °f) ---- engine coolant temperatur...
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Sv650k7/sk7/ak7/sak7 (’07-model) 171 fi sensors throttle body item specification note ckp sensor resistance 130 – 240 Ω ckp sensor peak voltage 3.7 v (when cranking) and more iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.5 v at idle speed tp sensor input voltage 4.5 – 5.5 ...
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172 sv650k7/sk7/ak7/sak7 (’07-model) electrical unit: mm (in) item specification note firing order 1.2 spark plug type ngk: cr8e denso: u24esr-n gap 0.7 – 0.8 mm (0.028 – 0.031 in) spark performance over 8 mm (0.3 in) at 1 atm. Crankshaft position sensor resistance 130 – 240 Ω bi – g ignition coil r...
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Sv650k7/sk7/ak7/sak7 (’07-model) 173 wattage unit: w item specification sv650sa sv650a e-03, 24, 28, 33 others headlight hi 60 × 2 60 ← lo 55 × 2 55 ← parking or position light 5 × 2 5 brake light/taillight led ← ← turn signal light 21 ← ← license light 5 ← ← speedometer light led ← ← tachometer lig...
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174 sv650k7/sk7/ak7/sak7 (’07-model) brake + wheel unit: mm (in) item standard limit rear brake pedal height sv650 50 – 60 (1.97 – 2.36) ---- sv650s 60 – 70 (2.36 – 2.76) brake disc thickness front 4.5 (0.18) 4.0 (0.16) rear 5.0 (0.20) 4.5 (0.18) brake disc runout ---- 0.3 (0.012) master cylinder bo...
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Sv650k7/sk7/ak7/sak7 (’07-model) 175 tire suspension unit: mm (in) item std/spec. Limit cold inflation tire pressure (solo riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- rear 250 kpa (2.50 kgf/cm², 36 psi) ---- cold inflation tire pressure (dual riding) front 225 kpa (2.25 kgf/cm², 33 psi) ---- r...
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176 sv650k7/sk7/ak7/sak7 (’07-model) fuel + oil item std/spec. Note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10% ethanol, or less than 5% methanol...
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Wiring diagram sv650k7 (for e-02, 19, 24, 33) wiring diagrams wire color, refer to sv650/s service manual section “wire color”. . Bl/y r o/g w/r gr/r b/w speedometer l n o r b f r : turn signal indicator light (r) l : turn signal indicator light (l) b : hi-beam indicator light f : fuel indicator lig...
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Sv650k7 (for e-03, 28) b/br bl/w bl/b bl/g bl/y r o/w w/r gr/r b/w b b/w b b/w y b/w w lg b/w lg b/w speedometer l n o r b f r : turn signal indicator light (r) l : turn signal indicator light (l) b : hi-beam indicator light f : fuel indicator light o : oil indicator light m on off lock p 1 off on o...
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Sv650sk7 (for e-02, 19, 24, 33) b/br bl/w bl/b bl/g bl/y r o/g w/r gr/r b/w speedometer l n o r b f r : turn signal indicator light (r) l : turn signal indicator light (l) b : hi-beam indicator light f : fuel indicator light o : oil indicator light m on off lock p 1 off on oil pressure switch off on...
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Sv650sk7 (for e-03, 28) b/br bl/w bl/b bl/g bl/y r o/w w/r gr/r b/w speedometer l n o r b f r : turn signal indicator light (r) l : turn signal indicator light (l) b : hi-beam indicator light f : fuel indicator light o : oil indicator light m on off lock p 1 off on oil pressure switch off on off run...
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Sv650ak7 (for e-02, 19, 24, 33) b/br bl/w bl/b bl/g bl/y r o/g w/r gr/r b/w o b/y o/y w/r bl gr/r w/y b/r b/w r/b r b/w b b/w b b/w br b/w br b/w y b/w w lg b/w lg b/w speedometer l n o r b f r : turn signal indicator light (r) l : turn signal indicator light (l) b : hi-beam indicator light f : fuel...
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Sv650ak7 (for e-03, 28) b/br bl/w bl/b bl/g bl/y r o/w w/r gr/r b/w b b/w b b/w y b/w w lg b/w lg b/w speedometer l n o r b f r : turn signal indicator light (r) l : turn signal indicator light (l) b : hi-beam indicator light f : fuel indicator light o : oil indicator light m on off lock p 1 off on ...
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Sv650sak7 (for e-02, 19, 24, 33) b/br bl/w bl/b bl/g bl/y r o/g w/r gr/r b/w o b/y o/y w/r bl gr/r w/y b/r b/w r/b r b/w br b/w br b/w speedometer l n o r b f r : turn signal indicator light (r) l : turn signal indicator light (l) b : hi-beam indicator light f : fuel indicator light o : oil indicato...
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Sv650sak7 (for e-03, 28) b/br bl/w bl/b bl/g bl/y r o/w w/r gr/r b/w o b/y w/r bl gr/r w/y b/r b/w r/b r b/w br b/w br b/w speedometer l n o r b f r : turn signal indicator light (r) l : turn signal indicator light (l) b : hi-beam indicator light f : fuel indicator light o : oil indicator light m on...
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Prepared by october, 2006 part no. 99501-36140-01e printed in japan 176 sa mp le.
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Printed in japan k7.